There used to be a time when manufacturing equipment was only repaired. Now, with more sophisticated and advanced machines, there is the opportunity to run proactive maintenance.
Proactive maintenance can help companies keep their operations running smoothly with fewer interruptions for equipment repair, which could negatively impact business goals.
What is Proactive Maintenance?
There are different options for companies to consider when they want to take care of their equipment.
- Preventative Maintenance: Maintenance work is completed at regular intervals. The intervals can be based on a calendar or usage.
- Condition-Based Maintenance: Maintenance is performed when sensors show that the equipment is experiencing an issue.
- Predictive Maintenance: A combination of condition monitoring sensors and machine learning to forecast when a machine is likely to fail. Like a warning system, this gives maintenance personnel alerts or notifications, so workers have time to schedule a repair before failure occurs.
- Prescriptive Maintenance: Machines use sensors and analytics to perform self-diagnosis and provide technicians with solutions on how to deal with the identified issue(s).
The Positive Impact of Proactive Maintenance
When considering the many benefits of proactive maintenance, don’t forget these key areas:
- Reduced delays in production due to equipment repair
- Improved equipment durability, reliability
- Reduced maintenance costs – including labor time
- Fewer safety issues
- Increased lifespan or longevity of equipment
With so many benefits that speak to the safety of employees and the profitability of the company, it might seem like a no-brainer to go ahead and start proactive maintenance right away. Unfortunately, it will take some planning to properly implement.
Proactive Maintenance Implementation Requirements
To implement a successful maintenance strategy, be sure to consider these requirements.
Commitment from Upper Management
Just like any strategic initiative, the higher-ups in the organization have to be on board. Communicating the short and long-term benefits is a key to making this happen. If the cost will be a hard selling point, the preventative maintenance approach might be the easiest to sell.
Understanding Capabilities of the Maintenance Department
Before dreaming of implementing proactive maintenance, a clear understanding of the current maintenance strategy is a must. Work with the maintenance managers to conduct an analysis of the current strategy. Consider what is working well, what could be improved, and how the team can go about implementing one (or more) of the proactive maintenance strategies. Everything from budget to technologies to personnel must be considered during this brainstorming and planning phase.
Cloud-Based CMMS Software
Proactive maintenance checks rely on tracking and analyzing data. This requires a computerized maintenance management system (CMMS) to be able to hold this level of data. With this software, companies can easily track maintenance schedules, failure patterns, service history, and other key performance indicators. If the company doesn’t already have CMMS, it will need to include this aspect in the implementation plan.
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